Adjustable Bed Foundation

ABSTRACT

The present invention is a bed foundation that, in one embodiment, eliminates the need for a separate frame and box spring. In addition, by employing cross beams of different lengths, the bed foundation of the present invention can be adjusted to fit varying mattress sizes.

FIELD OF THE INVENTION

The present invention is related generally to the field of bed structures and more specifically, to a bed foundation that can be configured to make beds of different sizes.

BACKGROUND OF THE INVENTION

Beds generally comprise a mattress and box spring, which lies upon a frame consisting of at least four extended members that connect together at the corners to form a rectangle. Each member typically includes a protruding ledge for holding the box spring which supports a mattress placed thereon. The spaced parallel protruding ledges support the outer periphery of the box spring mattress. Although sufficient for most beds that are smaller in size, the rectangular configuration fails to sufficiently support the center of most large beds, such as queen or king-sized beds. Up to 70% of the weight of a sleeper rests on the center “support zone” of the bed and a lack of support in the support zone can result in bowing of the mattress and instability. Such bowing and instability of the mattress can result in discomfort for the sleeper and excessive wear on the mattress and bed frame.

A common approach to providing support to the center zone of the bed is to use a plurality of wooden slats that rest on the side bars of the frame and extend along the width of the bed. However, wooden slats are generally undesirable due to their lack of rigidity and tendency to sag, warp or break after extended exposure to the weight of the bedding and/or the sleeper. Further, this arrangement may lead to instability at the ends where the box springs are not supported by the wooden slats.

Undue sag or deflection of mattress and box spring support may be avoided by using stiffer materials, such as metal rails in place of the wood slats. Although an improvement over wooden slats, metal cross-rails and bed frames of varying sizes are needed to fit each individual type of bed size. Given the large number of bed widths, retailers frequently encounter the problem of having too many, or too few, of a certain type of frame and cross-rails.

Conventionally, box springs are important because it supports the comfort of the overlaid mattress and a lack of a proper box spring support results in premature compaction and deterioration of the padding layers in a mattress, which may precipitate the need for buying a new mattress again. However, buying a new box spring incrementally increases the cost of mattress for a user. Moreover, box springs are large, difficult to transport, not amenable to partition (for easier shipping), and not fully fire-resistant.

It would be advantageous to have a bed foundation that eliminates the need for using separate frames and box springs for varying sizes of mattresses. There is also a need for a bed foundation that not only provides good support, but is also fire-resistant, easy to manufacture and install, easy to transport, and requires a minimal number of parts.

SUMMARY OF THE INVENTION

The present invention is directed towards a bed foundation that, in one embodiment, eliminates the need for a separate frame and box spring. In addition, by employing cross beams of different lengths, the bed foundation of the present invention can be adjusted to fit varying mattress sizes. In one embodiment, the bed foundation of the present invention eliminates the need for a separate frame and box spring and can be configured to create various bed sizes.

One embodiment of the present invention is a bed foundation kit that comprises four corner pieces wherein each corner piece comprises a frame made of a first rectangle having four corners and a second rectangle having four corners, wherein each corner of the first rectangle is attached to each corresponding corner of the second rectangle by a lateral member, and wherein said frame has at least one corner with an exposed hole and a plurality of cross beams of different lengths wherein the end of at least one cross beam is tapered to fit into said exposed hole; and wherein the combined length of two corner pieces and at least one cross beam is in the range of approximately 70 inches to 88 inches and wherein the combined width of two corner pieces and at least one cross beam is in the range of approximately 34 inches to 80 inches.

Optionally, each of the corner pieces is approximately 7 inches high, approximately 28 inches long, and approximately 12 inches wide. The two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 38 inches wide and 74 inches long. The two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 38 inches wide and 80 inches long. The two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 54 inches wide and 74 inches long. The two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 54 inches wide and 80 inches long. The two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 60 inches wide and 80 inches long. The two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 76 inches wide and 80 inches long. The two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 72 inches wide and 84 inches long.

Optionally, the bed foundation further comprises four legs, each of which is connected to one of the four corner pieces. Alternatively, the bed foundation further comprises four wheels, each of which is connected to one of the four corner pieces.

In another embodiment, the bed foundation comprises four corner pieces wherein each corner piece comprises a frame made of a first rectangle having four corners and a second rectangle having four corners, wherein each corner of the first rectangle is attached to each corresponding corner of the second rectangle by a lateral member, and wherein said frame has at least one corner with an exposed hole; and a plurality of cross beams of different lengths wherein the end of at least one cross beam is tapered to fit into said exposed hole; wherein the cross beams physically interconnect with said four corner pieces to create said bed foundation.

Optionally, each corner piece is approximately 7 inches high, approximately 28 inches long, and approximately 12 inches wide. The cross beam is used to connect two corner pieces together along a length of said foundation and has a length of approximately 18 inches. The cross beam is used to connect two corner pieces together along a width of said foundation and has a length of approximately 14 inches.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be further appreciated, as they become better understood by reference to the detailed description when considered in connection with the accompanying drawings:

FIG. 1 illustrates one embodiment of the bed foundation of the present invention;

FIG. 2 illustrates a perspective view of one embodiment of the foundation structure of the present invention;

FIG. 3 is a depiction of the finished bed foundation of the present invention, covered by a foundation cover;

FIG. 4 illustrates the dimensions and one exemplary arrangement of the cross beams with the corner pieces to form a twin-sized bed foundation, in accordance with the present invention;

FIG. 5 illustrates the dimensions and one exemplary arrangement of the cross beams with the corner pieces to form a queen-sized bed foundation, in accordance with the present invention;

FIG. 6 a illustrates a method of packaging the corner pieces longitudinally, for shipping ease; and

FIG. 6 b illustrates a method of packaging the corner pieces laterally, for shipping ease.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed towards a bed foundation that, in one embodiment, eliminates the need for a separate frame and box spring. In addition, by employing cross beams of different lengths, the bed foundation of the present invention can be adjusted to fit varying mattress sizes. In one embodiment, the bed foundation of the present invention eliminates the need for a separate frame and box spring and can be configured to create various bed sizes.

In another embodiment, the present invention is directed towards a bed foundation that comprises four corner pieces and a set of cross beams. The bed foundation is shipped unassembled and thus allows for facile and cost-effective shipping. Therefore, the bed foundation kits can be sold that comprise a) a set of cross beams, b) corner pieces, c), optionally, attachment bolts, screws, or clamps and d), optionally, one or more foundation covers of varying dimensions.

Various modifications to the preferred embodiment will be readily apparent to those of ordinary skill in the art, and the disclosure set forth herein may be applicable to other embodiments and applications without departing from the spirit and scope of the present invention and the claims appended hereto.

Reference will now be made to specific embodiments of the present invention. The embodiment described herein is not a general disavowal of any one specific embodiment or used to limit the claims beyond the meaning of the terms used therein.

Referring now to FIG. 1, one embodiment of the bed foundation of the present invention is shown. In one embodiment, the bed foundation comprises a plurality of corner pieces 110 a, 110 b, 110 c and 110 d, and a plurality of cross beams 120. In one embodiment, the bed foundation comprises four corner pieces. In one embodiment, the corner pieces 110 a, 11 b 110 c, and 110 d and the plurality of cross beams 120 are constructed from metallic materials such as steel or angle iron. However, one of ordinary skill in the art would appreciate that the bed foundation may be manufactured using any other suitable, sturdy material.

As shown in FIG. 1, each of the corner pieces 110 a, 110 b, 110 c, and 110 d is formed by two substantially rectangular members 112 and 113, joined together by four longitudinal members 114. This construction gives the corner pieces a generally cubic shape, similar to hollow building blocks. In using this type of structure, the corner pieces are sturdy, without requiring them to be too heavy. More specifically, assembling the corner pieces in this manner allows for a bed foundation that is easy to assemble, easy to ship, and cost-effective to ship. Preferably, the edges of the corner pieces facing outward 116 are curved or rounded to avoid sharp edges.

Each of the four corner pieces comprise a frame made of a first rectangle having four corners and a second rectangle having four corners, wherein each corner of the first rectangle is attached to each corresponding corner of the second rectangle by a lateral member. The rectangles and lateral members are fixedly attached.

In one embodiment, corner pieces 110 a, 110 b, 110 c, and 110 d are integrated with a plurality of cross beams 120 to create the structure of bed foundation. The integration is preferably removable, thereby permitting the cross beams and the corner pieces to be readily physically separated. Preferably, the dimensions of each of the corner pieces remain the same while the dimensions of cross beams vary in order to create the various bed sizes.

FIG. 2 illustrates a perspective view of one embodiment of the foundation structure of the present invention. As shown in FIG. 2, a plurality of elongate cross beams 210 are connected to the outer edge of the four corner pieces 220 a, 220 b, 220 c, and 220 d, forming the periphery, or outer frame, of the bed foundation of the present invention. Additionally, a plurality of elongate cross-beams 230 are connected to the inner edges of the four corner pieces to provide support to the center zone of the bed.

In the embodiment shown in FIG. 2, two elongate beams 230 a and 230 b extend parallel to each other along the width of the bed, while cross beam 230 c lies across the length of the bed, perpendicular to the two parallel beams. It should be appreciated that the number, dimensions, as well as the arrangement of cross beams 230 in the center zone of the bed foundation may be varied to create support structures suitable for various bed sizes. The dimensions of the elongate beams in the periphery and in the center zone of the bed foundation define the overall length and width of the bed. In this manner, the bed foundation may be configured for beds of various sizes, simply by varying the dimensions and arrangement of cross beams 210 and 230.

In one embodiment, the corner pieces may be connected to the cross beams using any attachment means, including but not limited to male/female mating members, locking members, bolts, screws, clamps, or threaded fasteners. The use of such attachment means lends more portability, and enhances the ease of packaging and shipping the corner pieces and cross beams. In addition, the use of removably attachable means enhances the ease of assembly for the consumer or other user of the bed foundation. In one preferred embodiment, the ends of the cross beams are tapered to fit into the holes located at the corners of the corner pieces.

FIG. 3 is a depiction of the finished bed foundation 300 of the present invention, which can be used with varying mattress sizes. In one embodiment, the bed foundation of the present invention 300 does not require a separate bed frame and box spring, and is ready to be used with any mattress. Optionally, wheels or legs (not shown) may be attached to the foundation so that it functions as a frame. Also, optionally, a kit for making the bed foundation, comprising of corner pieces and cross beams, also comprises a foundation cover, 305, fitted to cover the underlying foundation 300.

In one embodiment, the metallic foundation of the present invention may be covered with a layer of any suitable natural material such as, but not limited to, cotton canvas or natural latex. In another embodiment, the metallic foundation of the present invention may be covered with a layer of a suitable synthetic material such as, but not limited to, synthetic latex or polyester based materials. In yet another embodiment, the metallic foundation of the present invention may be covered with a layer of a hypo-allergenic material.

As mentioned previously, the bed foundation of the present invention can be configured to create beds of various sizes simply by varying the dimensions and arrangement of cross beams. Preferably, the dimensions of the corner pieces remain the same for any size bed and are optimized to balance competing design issues of size and weight, and sturdiness. Large corner pieces are less desirable, since a larger corner piece will contribute to the overall weight of the structure significantly, thereby increasing the transportation and/or shipping cost. Small corner pieces, on the other hand are also less desirable, because more stress is placed on the cross beams. In such conditions, the likelihood of failure of the foundation structure to support the mattress significantly increases. In the design of the present invention, the dimensions of corner pieces are designed to maintain optimal equilibrium between size, weight, and strength, and provide the most favorable bed foundation structure. Also, the structure of corner pieces, which is similar to that of hollow building blocks, lends robustness while at the same time keeping the weight low for ease of shipping and transport.

In one embodiment, each corner piece is between 4 and 10 inches high (more preferably 7 inches high), between 20 and 36 inches long (more preferably 28 inches long), and between 7 and 17 inches wide (more preferably 12 inches wide). The corner pieces can be combined with the cross beams, as mentioned above, to make any of the following known bed sizes (in inches): TWIN (38×74); TWIN LONG (38×80); FULL/DOUBLE (54×74); FULL LONG (54×80); QUEEN (60×80); EASTERN KING (76×80); and CALIFORNIA KING (72×84).

Notwithstanding the above-mentioned standard bed sizes, one of ordinary skill in the art would appreciate that the dimensions and arrangement of the corner pieces as well as cross beams may be custom manufactured to create any bed size.

FIG. 4 illustrates the dimensions and one exemplary arrangement of the cross beams with the corner pieces to form a twin-sized bed foundation, in accordance with the present invention. Referring to FIG. 4, each of the corner piece 410 a, 410 b, 410 c, and 410 d is 28 inches in length. Cross beams 420 and 430, which are used to connect the corner pieces together along the length of the foundation periphery, have a length of 18 inches. Thus, the overall foundation periphery length, on its longitudinal edge, is 74 inches. In order to obtain the desired width of 38 inches for a Twin sized bed, corner pieces 410 a, 410 b, 410 c, and 410 d, which are 12 inches wide, are joined across the width of the bed foundation by cross beams 440 and 450, each of which is 14 inches in length.

The center zone of the twin-sized bed foundation is, in one embodiment, supported by two pairs of cross beams 460 and 470. Cross beams 460 are 18 inches in length each and extend parallel to each other along the length of the bed foundation to join the inner corners of the corner pieces 410 a with 410 b and 410 c with 410 d. Cross beams 470 are 14 inches long each and extend parallel to each other across the width of the bed foundation to join the inner corners of the corner pieces 410 a with 410 c and 410 b with 410 d. It should be appreciated that any other arrangement of cross beams suitable for supporting the center zone of the bed may be made. Further, as illustrated in FIG. 4, legs 480 may optionally be attached to the bed foundation to attain a desired height for the bed. Optionally, legs 480 further comprise wheels.

FIG. 5 illustrates the dimensions and one exemplary arrangement of the cross beams with the corner pieces to form a queen-sized bed foundation, in accordance with the present invention. A typical queen-sized bed has the dimensions of 60 inches wide and 80 inches long. With each of the corner pieces 510 a, 510 b, 510 c, 510 d being 28 inches in length, the cross beams 520 and 530 joining the corner pieces along the length of the foundation periphery are 24 inches long each, to obtain the desired overall length of 80 inches for the bed foundation. For achieving the desired width of 60 inches for a queen-sized bed, corner pieces 510 which are 12 inches wide, are joined across the width of the bed foundation by cross beams 540 and 550, each of which is 36 inches in length.

The center zone of the queen-sized bed foundation is supported by two pairs of cross beams 560 and 570. Cross beams 560 are 24 inches in length each and extend parallel to each other along the length of the bed foundation to join the inner corners of the corner pieces 510 a with 510 b and 510 c with 510 d. Cross beams 570 are 36 inches long each and extend parallel to each other across the width of the bed foundation to join the inner corners of the corner pieces 510 a with 510 c and 510 b with 510 d. It may be noted that besides the arrangement illustrated in the embodiment shown in FIG. 5, any other arrangement of cross beams suitable for supporting the center zone of the bed may be made. Further, as illustrated in FIG. 5, legs 580 may optionally be attached to the bed foundation to attain a desired height for the bed. Optionally, legs 580 further comprise wheels.

In one embodiment of the bed foundation of the present invention, the corner pieces and the cross beams may be packaged and shipped separately and assembled later. FIGS. 6 a and 6 b illustrate two methods of packaging the corner pieces such that economy of space is achieved and the transportation cost is minimized. Referring to FIG. 6 a, two corner pieces 610 and 620 are packaged end to end, in a longitudinal manner. As each corner piece is 28 inches in length in the exemplary embodiment, therefore, the total length of the package is 56 inches.

Referring now to FIG. 6 b, two corner pieces 630 and 640 are shown packaged side to side, in a lateral manner. As each corner piece is 28 inches in length in the exemplary embodiment, the total length of the package is preferably larger, e.g. 29 inches, to allow for the extra space required for packaging in a box with padding. Additionally, it is preferable for the width of the package to be approximately 19 inches, taking into account the thickness of the members forming the corner pieces, while the height of the package is 13 inches approximately. Both the aforementioned methods of packaging conserve space and yield compact packages that can be shipped economically.

The above examples are merely illustrative of the many applications of the system of present invention. Although only a few embodiments of the present invention have been described herein, it should be understood that the present invention might be embodied in many other specific forms without departing from the spirit or scope of the invention. Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive, and the invention may be modified within the scope of the appended claims. 

1. A bed foundation kit comprising: four corner pieces wherein each corner piece comprises a frame made of a first rectangle having four corners and a second rectangle having four corners, wherein each corner of the first rectangle is attached to each corresponding corner of the second rectangle by a lateral member, and wherein said frame has at least one corner with an exposed hole; and a plurality of cross beams of different lengths wherein the end of at least one cross beam is tapered to fit into said exposed hole; and wherein the combined length of two corner pieces and at least one cross beam is in the range of approximately 70 inches to 88 inches and wherein the combined width of two corner pieces and at least one cross beam is in the range of approximately 34 inches to 80 inches.
 2. The bed foundation of claim 1 wherein each of the plurality of corner pieces is approximately 7 inches high, approximately 28 inches long, and approximately 12 inches wide.
 3. The bed foundation of claim 1, wherein two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 38 inches wide and 74 inches long.
 4. The bed foundation of claim 1, wherein two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 38 inches wide and 80 inches long.
 5. The bed foundation of claim 1, wherein two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 54 inches wide and 74 inches long.
 6. The bed foundation of claim 1, wherein two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 54 inches wide and 80 inches long.
 7. The bed foundation of claim 1, wherein two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 60 inches wide and 80 inches long.
 8. The bed foundation of claim 1, wherein two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 76 inches wide and 80 inches long.
 9. The bed foundation of claim 1, wherein two corner pieces and at least one cross beam are connected to form a bed foundation that is approximately 72 inches wide and 84 inches long.
 10. The bed foundation of claim 1 further comprising four legs, each of which is connected to one of the four corner pieces.
 11. The bed foundation of claim 1 further comprising four wheels, each of which is connected to one of the four corner pieces.
 12. A bed foundation comprising: four corner pieces wherein each corner piece comprises a frame made of a first rectangle having four corners and a second rectangle having four corners, wherein each corner of the first rectangle is attached to each corresponding corner of the second rectangle by a lateral member, and wherein said frame has at least one corner with an exposed hole; and a plurality of cross beams of different lengths wherein the end of at least one cross beam is tapered to fit into said exposed hole; wherein the cross beams physically interconnect with said four corner pieces to create said bed foundation.
 13. The bed foundation of claim 12 wherein each corner pieces is approximately 7 inches high, approximately 28 inches long, and approximately 12 inches wide.
 14. The bed foundation of claim 12 wherein at least one cross beam is used to connect two corner pieces together along a length of said foundation.
 15. The bed foundation of claim 14 wherein said at least one cross beam has a length of approximately 18 inches.
 16. The bed foundation of claim 12 wherein at least one cross beam is used to connect two corner pieces together along a width of said foundation.
 17. The bed foundation of claim 16 wherein said at least one cross beam has a length of approximately 14 inches.
 18. A bed foundation comprising: four corner pieces wherein each corner piece comprises a frame made of a first rectangle having four corners and a second rectangle having four corners, wherein each corner of the first rectangle is fixedly attached to each corresponding corner of the second rectangle by a lateral member; and a plurality of cross beams wherein the cross beams removably physically interconnect with said four corner pieces to create said bed foundation. 